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Old 01-31-2016, 02:47 PM
kboehringer's Avatar
kboehringer kboehringer is offline
XS-XJ Guru
Join Date: May 2015
Location: Peachtree City, Georgia.
Posts: 1,014
Smile SS Mig or Tig - Absolute minimum heat & wire speed

Originally Posted by BillyRok View Post
...SNIP....anybody have other proven solutions or reasonable ideas?
In my opinion, Marty's suggestion of the dent puller is the best idea. BUT, you need to find someone that can weld using Stainless Steel Wire or TIG PROPERLY. The typical welder, very proficient with a traditional carbon steel stick or MIG weld, is not necessarily familiar with or use to working with SS & Aluminum welds. Some may not even have the proper shielding gases required for other metals.

I'm not sure if you saw the mod made to the Harley muffs on my DUCK at XSSE '15? I was able to cut the very nice chrome mufflers completely apart, remove several inches, and SS weld them back together with SS mig wire (and Tri-Mix Gas Shielding).

There is a TINY bit of discoloration (slight yellowing) of the chrome due to heat on the margin between the SS welds and the chrome. Most people have to be shown the discoloration to see it but it is visible in the photo above.

However, the mufflers I modified were absolutely perfect metal of very high quality (OEM H.D.). They had never been used and didn't have ANY corrosion, dirt, carbon, etc. on them inside or outside. I SUSPECT you could get comparable results if the metal is in REALLY nice condition and has been thoroughly cleaned. Considering where the dent is.... unlikely anyone would see a little discoloration, certainly not as visible as that dent!

I am a "pretty good" welder but I have had a heck of a time just repairing some of my head pipes. But, my best set of head pipes does not look anywhere near as nice & pristine as the one you have there! If those pipes were mine.... I'd drill a couple holes, pull the dent and fill the holes and any remaining indentation with SS wire.

Find a really good welder!

Kurt Boehringer
Peachtree City, Georgia

1970 - CT70K0 - Mini-Trail
1979 - XS1100SF - Pensacola
1980 - XS1100SG - The Duck
1980 - XS1100SG - Mayberry Duck
1981 - XS1100SH - DEAD Duck Café
1981 - XJ550 Maxim - Nancy's Mini-Max
1982 - XJ650 SECA - Hurricane
1986 - FJ1200 - - Georgia Maverick
1992 - FZR1000 - Genesis
2016 - FJR1300A - Montgomery

Last edited by kboehringer; 01-31-2016 at 02:53 PM. Reason: Spelling & Etc.
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